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How to install a 2nd Gen. air cleaner box in 1st Gen. PT.

 
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Old 13 Sep 2018, 08:24 pm
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Location: Ormond Beach, Fl. 32174
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Default How to install a 2nd Gen. air cleaner box in 1st Gen. PT.

With a little cuttin' and fittin' I got a 2nd Gen, air cleaner box installed in SOOO BIG. It can be done. If you make the conversion, let us know.
SOOO BIG seems to run a little stronger with this new set up but it might be the brand new air filter allowing him to breath a little deeper. I figure there's some reason why every PT from 2006 on up had this air cleaner box on right from the factory.
The change does give access to the battery posts that's not there with the 1st Gen set up. Additionally, I like the looks of the red top Optima battery peekin' out from under the air cleaner. That's good enough reason so for those of you that would like to do the swap, here's the short list of parts you'll need:
Except for the bolts, I picked everything up at our local LKQ salvage yard for less than $10.00. You'll need a complete 2nd Gen air cleaner box, 1st and 2nd Gen brackets, 2nd Gen EGR hose and four 6X32X1/2" bolts, washers and lock nuts. The following are reference photos.
Happy PTin', ptprice

(1) mounting hardware, four 6X32X1/2" bolts, washers and lock nuts . . .(2) 2nd Gen.bracket tang extension cut to 1 1/4" width. Do the cut off just above bottom rolled edge. 9/64" drill holes, four bolt pattern, two top, two bottom.
l1.jpg2.jpg
(3) Modified 1st Gen bracket, center tang cut, bent straight and drilled . . .(4) Modified assembled 1st Gen. bracket test fit
l3.jpg4.jpg
(5) Before and after side by side comparison of difference in center tangs. . .(6) The measurement to top of 2nd Gen bracket tang addition should be 5 1/2" when installed. This height is critical in keeping the bracket tang functioning as original because the rear of the 2nd Gen, air cleaner box rests on the bend of the tang.
l5.jpgl6.jpg
(7) Modified 1st Gen, bracket installed . . . (8) 2nd Gen air cleaner box installed
l7.jpgl8.jpg
(9) SOOO BIG's new look with the 2nd Gen air Box installed. . . (10) The EGR hose has to be replaced with the longer 2nd Gen hose
l9.jpgl10.jpg
__________________
SOOO BIG 2005 PT CRUISER, LIMITED EDITION, SIGNATURE SERIES
Custom Cool Vanilla White, 3 Coats. 2.4 DOHC 16V SMPI Eng. Vanity Cover, 4 Spd. Auto Trans. 2.6 Overall Top Gear, Lock-up Torque Converter. Aluminum Chrome Clad 16" X 6" Wheels, P250/55 R16 Cooper Touring tires, Touring Suspension. Chrome Package; Side Spears, Grills, Fuel Filler Door, Door Locks, Handles, PRND3-1 Bezel, Silver/Chrome Shift Ball/Knob, Bright Spoke Leather Tilt Steering Wheel. Chrome Tail Lights, 3/8" Belt Trim. Cruise Control, Power Mirrors, A/C, Deep Tinted Sun Screen Glass, Power Moon Roof, Fog and Back-Up Lights, Rear Spoiler, Variable Front Wipers W/Washers, Rear Wiper/Washer, Key less Entry, Replacement 2001 Dark Taupe Grey Suede/Leather Trim Seats, Dual Under Seat Storage Drawers, Drivers Side Power Seat Height Adjust. Full Length Console, Locking Glove Box, Overhead Temperature/Compass Console, Rear Shelf Panel, AM/FM CD GPS Navigation Radio, 6 Premium Speakers, Back up Camera/ 7" Monitor.

Last edited by ptprice; 15 Sep 2018 at 02:12 pm.
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